Mattress and method of making the same



Nov 3, 1925 w. H. KELsEY MATTRESS AND METHOD OF MAKING THE SAME 2 Sheets-Sheet l Filed April ll. 1924 INVENTOR fa/66g.

Nov. 3, 1925# Y w. H. KELSEY MATTRESS AND METHOD oF MAKING THE SAME 2 sheets-sheet 2 Filed April l1. 1924 INVENTOR WSH. life/eey.

Patent-ed Nov. 3, 1925.

U N l T E D S T A T Es PATENT OFFICE.

WALTER HARRISON KELSEY, 0F HUTCI-IINSON, KANSAS.

MATTRESS AND METHOD OF -MAKING THE SAME.

Applicationled Api-i1 11, 1924. Serial No. 705,910.

To all whom it may concern.'

Be it known that I, WALTER I-I. KELsnY,

a citizen of the United States, residing atl Hutchinson,- in the county of Reno and'State of Kansas, have invented certain new' and useful Improvements in Mattresses and Methods of Making the Same, of which the following is a specification.

The invention relates to mattresses and has for its object to provide certain new and useful improvements therein due to the practice of a. new methodof construction, whereby a mattress is provided which is of a stretchless nature and which Will not lose its shape.

In the manufacture of mattresses one ofv the greatest diculties lies in the arranging and joining of the ticking thereof with relation to the boxing in a manner for preventing great bulging of sides and ends intermediately of the corners. This objectionable feature is commonly present in mattresses-iiow manufactured and when such mattresses stretch and expand they become unsightly and interfere with the desired neat appearance of beds upon which they are used.

Therefore, in its more detailed nat-ure the invention has for its object to provide a stretchless mattress structure and the same is produced by the peculiar method ofcutting and joining the ticking with the boxing in a manner whereby stretching and the loss of shape incident thereto are avoided.

With the above and other objects in View the invention further resides in those novel details of construction, combination and arrangement of parts, all of which will be first fully described, then be particularly pointed out in the appended claims, refer- .ence being had to the accompanying drawings, in which Figure 1 is a perspective view of the mattress boxing. 1 A

Fi ure 2 is a perspective view of one of the ticking sheets.

Figure 3 is a perspective view of the, ticking sheet after the same has been sewn.

Figure 4 is a detailcross section of one corner of the mattress formed by the meeting portions of the ticking and boxing showing the manner in which the same are sewn together. A

Figure 5 is a detail cross section similar to Figure 4 showing the mattress corner after the same is completed. j

Figure 6 is a detail diagrammatic perspective View illustrating the tucking Step of the construction method.

Figure 7 is a detail diagrammatic longitudinal section illustrating the manner of forming the edge rolls.

Figures 8 and 9 are diagrammatic plan Views illustrating completed mattresses embodying my invention and common methods respectively.

Figure 10 is a detail perspective view showing a completed mattress.

Figures 11 and 12 are diagrammatic perspective views illustrating the boxing and ticking sheet features of a modified form of the, invention respectively.

In vconstructing the mattress in accordance with myV invention I utilize an open substantially rectangular boxing l formed from a strip of suitable material of sufficient length to have the ends thereof sewed together for providing said boxingl in the manner clearly indicated in Figure l of the drawings.

For cooperating with the boxing in form- HEISSUED ing the mattress casing, top .and bottom.

ticking sheets 2 are provided, and, in the preferred form of the invention illustrated in Figures 1 to 7 inclusive of the drawings and in Figures 8 and l0, each of said ticking sheets is constructed in the manner clearly illustrated in Figure 2.

The ticking sheets are so formed by utilizing a rectangular sheet of the desired material, the said rectangle being of dimensions slightly'in excess of the dimensions of the boxing. For example, if the boxing dimentioiis cover an area of four feet six inches in has thus been formed a portion of each side thereof is cut-away on a curved line, from points adjacent the corners thereof, in a manner lindicated by the numeral 3 on Figure-2 and elsewhere in the drawings. Portions of the ticking are c'ut out in a manner for providing transverse curved slits 4. The ends 5 of the ticking are not cut but remain straight as originally, see Figure 2. After the transverse slits 4 have been cut as indicated'in Figure 2 of the drawings the end will be allowed to said slits are sewed together to form seams somewhat in the manner illustrated by the numeral 6 on Figure 3 of the drawings. The sewing together at 6 of the transverse 'curved slits 4 effects a pulling in of the formerly straight edges 5 so as to cause them to takea curved shapeindicated by the numeral 7 on Figure 3, and proportionately corresponding withthe curved sides formed by cutting and indicated, 3. It' should be understood that both the top and bottomfsheets, which cooperate with the boxin 1, are treated as just described in provi ing the casing for the improved mattress structure which is the subject of'my invention.

The edges of the top and bottom ticking sheets, formed as above described, are next tucked and sewed to the edges of the boxing l in the manner indicated by the numeral 8 in Figures 4 and 6 of the drawings, it being` understood, of course, that a portion of one remain vopen to per mit the proper stuffing of the mattress with any suitable stuffing material indicated by the numeral 9, after which that end will of course be tucked and sewed' as were all the remainin viding w at might be termed an over-stuffed mattress having surplus dimensions and not drawn in to its final shape but somewhat oversized as indicated in Figurev 4of the drawings. See Figure 6 for the tucking and sewing feature. I

In carrying Aout the next step in completing the mattress structure the edge materials are taken up along the. joining edges of said ticking and the vboxing by the heavy thread `10, sewed in zigzag fashion, across the said edge materials, especially-the ticking edge material, in a manner for roviding the roll 11 which extends around t e whole mattress structure at all of the edges thereof. The manner of forming this roll is clearly illustrated in Figure 5 of the drawings. The manner of sewing the thread in forming this roll is clearly illustrated in Figure 7 of the drawings, while Figure 10 illustrates the appearance of the completed product.

After the roll 11 has been formed as just described, the only remaining step necessary lto complete the mattress and thus form the structure illustrated in Figure 10, is the sewing of the usual tufts 12 which are suitably sewed and spaced in the manner common in mattress structure and for the purpose of confining the stung and providing the desired uniformity of top andv bottom mattress surfaces. The tufts 12 at that part of the mattress at which the seams 6 .occur may be positioned along said seams, and in this manner the said' seams are effectively hidden. e

In the manufacture of mattresses much diiculty is occasioned in trying to prevent the mattress from bulging and losing its edges of the said parts, thus prodesired shape, the common fault of such mattresses being indicated diagrammatically will distend itself and stretch so as to causeV the boxing thereof to bulge out.

By reason of providing specially oonstructed ticking sheets of the shape illustrated in Figure 3 of the drawings, the mattress casing is provided which, when stuffed, can only expand to a predetermined desired dimension and cannot extend itself beyond that dimension and therefor. cannot lose its shape. Y

' It will be observed from Figures 11 and 12 of the drawings that the same broad purpose of my invention may be accomplishedl by providing the usual boxing illustr. ted in Figure 11 and cutting the tickingsheets 2 cooperativetherewith` as at 3 'and 13, to immediately form the saidl ticking to the ultimate shape desired without utilization of the transverse slit feature. This simpler method may be found practical in the construction of some cheaper types of Amat'- tresses, especiallythose in which plain unstriped material is used. However, Imprefer to construct the mattressin accordance with the illustration of Figures 1 to 7, because by so doing amore-perfect finished product is produced than would be possible by merely cuttingl the edges at 3 and 13.` By using thetransverse slit feature distortion of the stripes is prevented, especially in mattress structures where .the stripes of the material are positioned to run transversely of the mattress, in which event it would-beobvious that to cut but the material to form the curves 7, instead of forming the same by searningthe slits 4. as at 6, would result in the cutting away of a portion of the material so that when the kcurves 7 would be sewn Vto the boxing, the distortion would be readorlginal straight edge 5 by the seams 7 and thus forming the curves 6, the seams 6 being usually positioned to avoid the stripes, all distorted appearance of the mattress is pre-V vented.

By reason of tucking the edge of the ticking sheets and sewing them in this condition to the adjacent boxing edges, the surplus of material edge length, made necessary bv the provision of the curves at ends and sides. is eectivelv the material perfectly even around the whole of the'V mattress and thus provide a uniform and neat apnea-ring structure.

In forming the edge rolls 11 the heavy thread 10 is sewed zigzag through the boxing and ticking material edges, the tacks of the lon thread at one side being short While those of the other side are relatively llong, thus effectively accomplishing the roll forming function and effecting a. thread economy. See Figure `7.

In carrying out the preferred form of my invention, the steps of the method are in sequence as illustrated in Figures 1 'to 5 inelusive of the drawings, see also Figures 6 and 7. i

I have found that the particular tucking feature here disclosed is far superior to pleating or other methods since by the use of such other methods the finished mattress structure is not as smooth and even as the structure made possible by the utilization of this feature of myinvention.

From the foregoing description, taken in connection with the accompanying drawings, it is thought that the.. novel details ofconstruction, the manner of carrying out the invention and the advantages thereof will be readily apparent to those skilled in the art.

What I claim is:

1. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to Yform the mattress casing, and stuffing for filling the mattress casing, the said ticking having curves at the sides and ends thereof.

2. In a mattress, `a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, and stuing for filling the mattress casing,` the said ticking being shaped on a curve at each of the sides and ends, which curves extend inwardly from points adjacent each corner.

3. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, stuifing yfor filling the mattress casing, the said` ticking being of a dimension in excess of the dimension of the boxing and being formed with reduced side and end portions and havl' ing the edges tucked, and edge rolls sur-v rounding the mattress at the4 edges thereof, and formedby sewing through the ticking and boxing material adjacent the joined edges thereof.

4. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, and stuiling for filling the mattress casing, the said ticking being shaped on a curve at each of the sides and ends, which curves extend inwardly from points adjacent each corner, and being tucked, and being of dimensions in excess lof those of the boxing to-permit the provision of the ticking curve feature, and edge rolls surrounding the mattress at the edges thereof and formed by sewing through the ticking and boxing material adjacent the joined edges thereof.

5. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, and stuffing for illingthemattress casing, the said ticking having concaved sides and seams` formed transversely thereof to form concaved ends. i

6. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the'boxing to form the mattress casing, and stuiiing for filling the mattress casing, the

vsaid ticking being of a dimension in excess' of the boxingl and being formed with concaved sides and endsand having the said concaved edges tucked, and edge rolls surrounding' the mattress at the edges thereof and formed by sewingthrough the ticking and boxing material adjacent the joined edges thereof.

7. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, and stufiing for filling the mattress casing, the said ticking having concaved sides and seams formed transversely thereof to form concaved ends, the said concaved ends and sides being tucked, and being of dimensions in excess of those of the boxing to permit the provision of the ticking concave feature, and

vedge rolls surrounding the mattress at the jacent the transverse seams being positioned inconspicuous.

9. In a mattress, a substantially rectangular boxing, ticking adapted to be secured to the boxing to form the mattress casing, and stuiiing for filling the mattress casing, the

along the said seams to render the said seams said ticking having concaved sides and seams formed transversely thereof to form concaved ends, the said concaved ends and sides being tucked, and beingof dimensions in excess of those of the boxing to permit the provision of the ticking concave feature, edge rolls surrounding the mattress at the edges thereof and formed by sewing through the ticking and boxing material adjacent the joined edges thereof, and tufts sewed to and through the ticking and stuffing to shape the mattress top and bottom, those of the tufts adjacent the transverse seams bein positioned along the said seams to ren er the said seams inconspicuous.

10. In a mattress, a substantially rectangular boxing, striped ticking adapted to be secured to the boxingto form the mattress casing with the `weave of the ticking running erosswise of the mattress, and stuing for filling the mattress casing, the said ticking having curves at the sides and ends 5 thereof.

11. In a mattress, a substantially rectan# gular boxing, ticking adapted to be secured to the boxing to form n mattress casing, said ticking havlng weave running crosswise ,of the mattress, and stufiing for filling the casl0 ing, said ticking having concave sides and seams formed transversely thereof to consti` tute curved ends.

WALTER HARRISON KELSEY.- 

